Multi-panel collapsible container

ABSTRACT

A multi-panel collapsible container able to support the weight of the goods and provide a quick and easy access to the contents of the container from the sides and the top, the container is configured to be collapsed for ease of storage when not in use.

RELATED APPLICATIONS

This application claims priority to U.S. Provisional Patent Application 60/668,768 filed Apr. 6, 2006, which is incorporated herein by reference.

FIELD OF THE INVENTION

The invention relates generally to a collapsible tote. More specifically, the invention relates to a multi-panel bin formed of corrugated materials that can be easily assembled and collapsed when not in use.

BACKGROUND OF THE INVENTION

Many types of containers are used for holding goods during storage and transportation. These containers are made of various materials, such as cardboard, wood, metal, and plastics. However, many of the known containers have various disadvantages, such as moisture immersion, high cost, or excessive weight. Moreover, they are not always suitable for all environmental conditions, such as sunshine or hot environments, wet or humid conditions, cold or frozen conditions, and forming stacks with heavy loads. Therefore, there is a need or demand for a durable container that can be used in any kind of environment in which a container would be used. At the same time, the container must be cost efficient or economical, easily foldable without use of any glue, tape, nails, or tools, easily transportable as a flat piece or pieces, reusable, light weight, moisture resistant, washable, and capable of stacking to bear heavy loads for a relatively long period of time. The container should also be recyclable.

At present, most collapsible containers are made of cardboard, waxed cardboard, or thin plastics because thick plastic boards cannot be easily folded. Such containers usually utilize laminate layers or fillers to reinforce the side and end walls or corners of the box for better support. An example of this type of container is disclosed in U.S. Pat. No. 3,310,219 to Dlugopolski. However, the container is not strong enough to hold the various panels of the container together when the box is used in severe conditions, such as moisture, heat, and heavy load.

Some containers incorporate a tab and slot locking system. An example of inset tabs and the slots are shown in U.S. Pat. No. 3,310,219 to Dlugopolski, and U.S. Pat. No. 3,708,103 to Evants. Barbed tabs are used in U.S. Pat. No. 4,463,997 to Densen, and U.S. Pat. No. 3,991,932 to Carmel et al. These locks are designed for cardboard material that is relatively soft and flexible. The locking system of Densen is a combination of the tab-slot engagement and barbed tabs. The barbed tabs must be bent over at the box corner to assure the locking of the tab-slot engagement. Accordingly, the assembly of such box is relatively slow and such locking cannot be used on boxes of thicker plastic materials. Moreover, the tab-slot engagement or barbed tab locking systems typically become worn-out or weakened due to moisture immersion.

The containers referenced above do not permit access to their contents when the containers are stacked in close proximity to a ceiling or upper shelf Rather, the container generally must be removed from the shelf so the container may be accessed through the lid. Accordingly, removing items from prior art containers can often be time consuming and labor intensive.

SUMMARY OF THE INVENTION

In view of the shortcomings set forth above, it is an object of the invention to provide an improved foldable container that meets all requirements stated above.

It is another object of the present invention to provide a container that facilitates the quick assembly or disassembly of the box, while providing the container with enhanced strength and stability.

It is a further object of the present invention to provide a foldable container that will allow access to the contents of the container when the container is located in close proximity to a ceiling or top shelf.

The invention includes a multi-panel collapsible container able to support the weight of the goods and provide a quick and easy access to the contents of the container from the sides and the top, the container is configured to be collapsed for ease of storage when not in use.

The container includes a support structure, a first end, and a second end. A bottom insert may be positioned in the interior of the container to lock the ends of the container in place and provide additional support for the contents of the container.

The container walls are securely locked by the content of the container, rather than mechanically fastened. This configurations enables the contents of the container to be accessible from multiple sides and from the top. The container can also be easily collapsed when not in use. Moreover, the container can be quickly assembled without the need for additional materials like packing tape.

The components of the container are fabricated of an extrusion of laminated, profile, or corrugated paper sheets, die-cut, assembled, welded or glued.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention may be more completely understood in consideration of the following detailed description of various embodiments of the invention in connection with the accompanying drawings, in which:

FIG. 1 shows a top view of the flattened components of the container pursuant to the invention.

FIG. 2 shows a top view of the flattened components of the container integrally fastened by a wire pursuant to the invention.

FIG. 3 shows a top view of a partially assembled container pursuant to the invention.

FIG. 4 shows a top view of a partially assembled container with bottom insert pursuant to the invention.

FIG. 5 shows a top view of an assembled container with dust cover pursuant to the invention.

FIG. 6 shows a side view of a collapsed container pursuant to the invention.

FIG. 7 shows a side view of an assembled container pursuant to the invention.

FIG. 8 shows a side view of the bottom insert and dust cover of the container.

While the invention is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit the invention to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Container 10 is shown in FIG. 1. Container 10 includes a support structure 12, a first end 14, a second end 16, and a bottom insert 18. Support structure 12 includes a base 20, first sidewall 22, and second sidewall 24. Support structure 12 also includes a first flap 26 and a second flap 28. The area between first sidewall 22 and first flap 26 is defined by edge 30. Similarly, the area between second sidewall 24 and second flap 28 is defined by edge 32. Edge 30 includes a first margin 38 and a second margin 40. Edge 32 includes a first margin 34 and a second margin 36. Base 20 includes a first margin 42 and a second margin 44. Base 20, first sidewall 22, and second sidewall 24 are bounded by a front edge 46 and a back edge. First flap 26 is bounded by front edge 50 and back edge 52. Second flap 28 is bounded by front edge 54 and back edge 56. Edges 46, 48, 50, 52, 54, and 56 are shown parallel to one another, although this feature is not necessary for the invention.

First end 14 will now be discussed. End 14 includes side 58, bottom 60, extension 62, extension 64, and flap 66. Edge 68 is disposed between side 58 and flap 66. Aperture 70 is disposed in side 58. Handle 72 is located along the top side of aperture 70. The boundary between side 58 and handle 72 is defined by margin 74. Edge 68 is bounded by margin 76 and margin 78. The boundary between side 58 and bottom 60 is defined by margin 80. The boundary between side 58 and extension 64 is bounded by margin 69. The boundary between side 58 and extension 62 is bounded by margin 67. End 14 includes a first side 82 and a second side 84. Similarly, end 14 includes a top edge 86 and a bottom edge 88. Bottom 60 is defined by a first side 90 and a second side 92. Flap 66 and edge 68 each share a first side 94 and a second side 96.

The details of second end 16 will now be discussed. End 16 includes side 98, bottom 100, extension 102, extension 104, and flap 106. Edge 108 is disposed between side 98 and flap 106. Aperture 110 is disposed in side 98. Handle 112 is located along the top side of aperture 110. The boundary between side 98 and handle 112 is defined by margin 114. Edge 108 is bounded by margin 116 and margin 118. The boundary between side 98 and bottom 100 is defined by margin 120. The boundary between side 98 and extension 104 is bounded by margin 122. End 16 includes a first side 124 and a second side 126. Similarly, end 16 includes a top edge 128 and a bottom edge 130. Bottom 100 is defined by a first side 132 and a second side 134. Flap 106 and edge 108 each share a first side 94 and a second side 96.

Insert 18 includes a central portion 140 located between sides 142 and 144. A first margin 146 defines the boundary between portion 140 and side 142. A second margin 148 defines the boundary between portion 140 and side 144. An aperture 150 is disposed through portion 140. Aperture 150 is circular, but may comprise a variety of shapes while remaining within the scope of the invention. Insert 18 also includes a top side 152 and a bottom side 154. Top side 152 is generally parallel to bottom side 154.

During construction of container 10, a wire 156 generally forming the rectangular configuration of the perimeter of base 20 is attached to support structure 12, first end 14, and second end 16. First, a segment of wire 156 is positioned in close proximity to edge 30. Next, first flap 26 is rotated about to margin 38 and margin 40 such that first flap 26 rests against first sidewall 22. Flap 26 is then secured against sidewall 22 with adhesive, sonic welding, or other fastening means. An opposing segment of wire 156 is then positioned in close proximity to edge 32. Second flap 28 is then rotated about margin 34 and margin 36 so that second flap 28 rests against second sidewall 24. Flap 28 is then secured against sidewall 24 with adhesive, sonic welding, or other fastening means.

The process of securing first end 14 and second end 16 to wire 156 will now be discussed. A segment of wire between first sidewall 22 and second sidewall 24 is positioned against edge 68 of first end. Flap 66 is then rotated about margins 76 and 78 so that flap 66 rests against side 58. Flap 66 is secured to side 58 by adhesive, sonic welding, or other suitable fastening means. Similarly, edge 108 is positioned in close proximity to the segment of wire 156 opposite to first end 14. Flap 106 is rotated over wire about margins 116 and 118 so that flap 106 rests against side 98. Side 98 is attached to flap 106 by adhesive, sonic welding, or other suitable fastening means. In this configuration, support structure 12, first end 14, and second end 16 are rotatably fastened to wire 156 in a collapsed form, as shown in FIGS. 2 and 6.

The assembly of container 10 will now be discussed. Support structure 12 is rotated so that sidewall 22 and sidewall 24 form 90-degree angles with base 20. Next, extensions 62 and 64, and bottom 60 are folded inward toward support structure 12 so that extensions 62 and 64, and bottom 60 form 90-degree angles with side 58. Margin 80 of end 14 is then moved against back edge 48 while extensions 62 and 64, and bottom 60 move into the interior of the container defined by sidewalls 22, 24, and base 20. Next, sides 124 and 126, and bottom 100 are folded inward toward support structure 12 so that sides 124 and 126, and bottom 100 for 90-degree-angles with side 98. Margin 120 of end 16 is then moved against front edge 46 while sides 124 and 126, and bottom 100 move into the interior of the container defined by sidewalls 22, 24, and base 20. This configuration is shown in FIGS. 3 and 7.

Next, side 142 and side 144 of bottom insert 18 are folded upwardly so sides 142 and 144 form approximately 90-degree angles with respect to central portion 140. Insert 18 is then positioned in the interior of container 10 so that central portion 140 rests against base, bottom 60, and bottom 100 as shown in FIG. 4. Handles 72 and 112 may optionally be folded inward to provide additional comfort for persons moving container 10.

A second insert 18 may be used as an optional dust cover by folding sides 142 and 144 at approximately a 90-degree angle with respect to central portion 140. Second insert 18 and optional dust cover 158 are shown in FIG. 8. Sides 142 and 144 are then slid between sidewalls 22 and 24 so that central portion 140 is located in a plane approximately parallel to edges 30 and 32. This configuration is shown in FIG. 5.

To access the contents of container 10, it is not necessary to remove cover 158. Rather, a user may pull margin 80 away from support structure 12 by pulling side 58 outward using aperture 70. This aspect of the invention is especially useful if container 10 is located on a high shelf so that cover 158 is close to a ceiling of a storage room. This configuration is also useful to access the contents of container 10 when several items are stacked on top of container 10. Perforation lines 160 and 162 are disposed in end 14 parallel to margin 80. Lines 160 and 162 facilitate the bending of end 14 that is helpful to manipulate end 14 into a variety of positions. For example, lines 160 and 162 enable a user to more easily fold bottom 60 between cover 158 and the base 20 of another container 10 resting atop cover. Similar perforation lines 164 and 166 are located in second end 16.

Wire 156 is preferably fabricated from galvanized metal to inhibit oxidation. Wire 156 may comprise a variety of thicknesses while remaining within the scope of the invention. In a preferred embodiment, wire 156 is at least 1 mm thick. A plastic wire may also be used.

Support structure 12, first end 14, second end 16, and bottom insert 18 may comprise a variety of materials while remaining within the scope of the invention. In a preferred embodiment, support structure 12, first end 14, second end 16, and bottom insert 18 are fabricated from corrugated paperboard, cardboard, or corrugated plastic. More specific examples include high density polyethylene (HDPE) laminate board, high density polyethylene (HDPE) profile board, polypropylene profile board, or corrugated paper.

When assembled sides 82 and 84 of first end 14 meet evenly with edges 50 and 52 of first flap. This creates a smooth, even inner profile of the container. Similarly, sides 124 and 126 meet evenly with edges 54 and 56 to create a smooth, even inner profile of the container. This type of finish increases the desirability of the overall container.

Although the invention has been described with reference to preferred embodiments, workers of ordinary skill will recognize that changes can be made in form and detail without departing from the spirit and scope of the invention. 

1. A method of removing items from a foldable container comprising the steps of: providing a support structure including; a base, a first sidewall, and a second sidewall; a rectangular-shaped frame pivotally attached to the first sidewall at a margin of the first sidewall opposite the base and pivotally attached to the second sidewall at a margin of the second sidewall opposite the base to define an interior, an exterior, top, front and back; a first end including a side and a bottom, wherein the side is pivotally attached to the frame at the front of the container, wherein the bottom of the first end is disposed against the base of the container to close the front of the container; a second end including a side and a bottom, wherein the side is pivotally attached to the frame at the back of the container, wherein the bottom of the second end is disposed against the base of the container to close the back of the container; rotating the first end about the frame such that the bottom of the first end moves to the exterior of the container; passing items from the interior of the container to the exterior of the container through the front of the container. 